Filter Monitoring Device, Air Flow System and Corresponding Methods

Abstract

A filter monitoring device for an air flow system is described herein, which comprises a circuit board comprising a first pressure measurement component and a second pressure measurement component, and including hardware and software configured to communicate pressure measurements to a remote computer. The device also includes a sensor comprising a first pressure sensor component comprising a first tube having a first end portion configured to be connected to the circuit board and a second end portion configured to be connected to a first location in the air flow system upstream from and external to a filter media compartment, and a second pressure sensor component comprising a second tube having a first end portion configured to be connected to the circuit board and a second end portion configured to be connected to a second location in the air flow system downstream from and external to the filter media compartment. Corresponding systems and methods also are disclosed.

1 . A filter monitoring device for an air flow system, comprising:
 a circuit board comprising a first pressure measurement component and a second pressure measurement component, and including hardware and software configured to communicate pressure measurements to a remote computer, and   a sensor comprising:
 a first pressure sensor component comprising a first tube having a first end portion configured to be connected to the circuit board and a second end portion configured to be connected to a first location in the air flow system upstream from and external to a filter media compartment, and 
 a second pressure sensor component comprising a second tube having a first end portion configured to be connected to the circuit board and a second end portion configured to be connected to a second location in the air flow system downstream from and external to the filter media compartment. 
   
     
     
         2 . The filter monitoring device of  claim 1 , wherein the circuit board software is configured to determine whether the pressure difference detected between the first and second pressure sensor components is greater than a first pressure difference. 
     
     
         3 . The filter monitoring device of  claim 1 , wherein the circuit board software is configured to determine continuous or periodic pressure difference measurements between the first and second locations in the air flow system. 
     
     
         4 . The filter monitoring device of  claim 2 , wherein the filter monitoring device is configured to electronically transmit a signal to the remote computer when the difference between the first and second pressure sensor components is greater than the first pressure difference. 
     
     
         5 . The filter monitoring device of  claim 3 , wherein the filter monitoring device is configured to periodically electronically transmit pressure difference measurements to the remote computer. 
     
     
         6 . The filter monitoring device of  claim 1 , further comprising a housing configured to contain the circuit board, first end portion of the first tube, and first end portion of the second tube. 
     
     
         7 . The filter monitoring device of  claim 3 , wherein the housing is configured to be mounted to a duct located proximate the filter. 
     
     
         8 . The filter monitoring device of  claim 3 , wherein the housing comprises at least one of a thermoplastic material and a thermoset material. 
     
     
         9 . The filter monitoring device of  claim 1 , wherein the remote computer comprises at least one of a smartphone, tablet computer, laptop computer, desktop computer and pager. 
     
     
         10 . The filter monitoring device of  claim 1 , wherein the pressure sensor comprises at least one of a piezoresistive sensor, a piezoelectric sensor, a capacitive sensor, and an electromagnetic sensor. 
     
     
         11 . The filter monitoring device of  claim 1 , wherein the first pressure sensor comprises a piezoresistive sensor. The filter monitoring device of  claim 1 , where output of a current clamp is connected to the device circuit board, the current clamp being attached to an electrical input of an air handler blower motor 
     
     
         13 . An air flow system comprising:
 a duct,   a blower configured to move air through the duct,   a compartment containing filter media configured to remove particulates from the air moving through the duct, and   a filter monitoring device that includes:   a circuit board comprising a first pressure measurement component and a second pressure measurement component, and including hardware and software configured to communicate pressure measurements to a remote computer, and   a sensor comprising:
 a first pressure sensor component comprising a first tube having a first end portion configured to be connected to the circuit board and a second end portion configured to be connected to a first location in the air flow system upstream from and external to the filter media compartment, and 
 a second pressure sensor component comprising a second tube having a first end portion configured to be connected to the circuit board and a second end portion configured to be connected to a second location in the air flow system downstream from and external to the filter media compartment. 
   
     
     
         14 . The system of claim  12 , wherein the air flow system is a residential system. 
     
     
         15 . The system of claim  12 , wherein the filer monitoring device is contained in a housing mounted to the duct by magnets. 
     
     
         16 . A filter monitoring device installed external to a filter media compartment, wherein flexible tubing is routed to a first location upstream from the filter media and a second location downstream from the filter media and to a circuit board internal to the device, wherein the circuit board contains components configured to measure a pressure difference between the first location and the second location. 
     
     
         17 . The filter monitoring device of  claim 16 , wherein the circuit board executes predefined software instructions to determine filter air flow restriction, and wherein the circuit board initiates wireless communications with at least one of a wireless electronic device and an external internet server. 
     
     
         18 . The filter monitoring device of  claim 17 , wherein the flexible tubing includes first and second tubes terminating upstream and downstream from the filter media, the tubes being positioned in tube connections that penetrate furnace ductwork upstream and downstream from the filter media, and wherein the filter monitoring device derives static pressure variants from first and second tubes. 
     
     
         19 . The filter monitoring device of  claim 17  wherein the pressure difference is measured using piezo-resistive sensing elements that transmit digital signals to a software controlled micro-controller mounted to the circuit board. 
     
     
         20 . The filter monitoring device of  claim 17 , wherein the device is configured to continuously execute software instructions to determine filter media air flow resistance by use of algorithms and variables. 
     
     
         21 . The filter monitoring device of  claim 20 , wherein the variables are established during device setup. 
     
     
         22 . The filter monitoring device of  claim 17 , wherein the device is configured to connect wirelessly to a remote computer to initiate device setup, by means of downloaded device application, for software variables of
 connection credentials to a local area network to allow connection to an external internet server,   device calibration upon filter replacement per filter ratings and actual flow resistance inherent with new filter media, and   maximum expected blower air movement in feet per minute.   
     
     
         23 . The filter monitoring device of  claim 17 , further comprising a series of 3-6 light emitting diodes (LED) illuminating from the surface of a device case, where each LED represents a different level of air flow resistance of the filter media. 
     
     
         24 . The filter monitoring device of  claim 17 , further including magnetic mounts configured to mount the case to metal ductwork.